Method for making debris-free nail collation

ABSTRACT

A method for making a collated fastener assembly includes arranging a plurality of fasteners in a row parallel to one another, in a plane, and spaced from one another, preheating the fasteners, applying a molten polymer material onto the fasteners and conveying the fasteners with the polymer into a mold cavity. The fasteners are maintained in the plane. The polymer is molded onto the fasteners and between adjacent fasteners to form a molding having a collar encircling a shank of each fastener and a connecting portion between adjacent fasteners. The molding maintains the space between the fasteners. A cooling stream is introduced onto the fasteners and the molding as the fasteners and the molding exit from the mold cavity.

BACKGROUND OF THE INVENTION

The present invention pertains to debris-free fastener collations. Moreparticularly, the present invention pertains to a method for making adebris-free collated nail strip formed with a plastic material for usein a fastener driving tool.

Fast-acting fastener driving tools are in widespread use in theconstruction industry and used in industries ranging from pre-fabricatedhousing construction to luxury residential, commercial and industrialconstruction.

The nails that are used in these tools are assembled in strips that areinserted into a magazine. There are two principal nail strip or nailcollation formations—paper tape and plastic. As the name suggests, papertape collations maintain the nails in a strip by using a strip of tapethat is adhered to one or both sides of the arranged nails. Plasticcollations use a formed or pre-formed collar-type element to secure thefasteners to one another and parallel in the strip form.

Paper tape has certain advantages, one of which is ease of manufacture.In addition, paper tape collations, which us a glue or adhesive toadhere the tape to the fasteners, tend to be quite rigid, butsufficiently easy to separate one fastener from an adjacent fastener, aswhen the fastener is driven from the tool into a substrate. Whilerigidity on the one hand is good for the collation in that it reducesthe opportunity for strip corrugation, on the other hand, it tends torequire additional force to separate the fastener from the strip.Moreover, paper tape collations also produce a significant amount ofdebris when the fastener is separated from the strip. This debris cancause increased tool maintenance as well as jamming and increaseddown-time for tool repair.

Plastic collations use a collar that is molded to or fit around theshank of the fasteners. The collars are connected by bridges that breakor separate to permit the fastener to be separated from the strip. Onedrawback to commonly available plastic collations is that the collation,although molded around the fastener, is nevertheless only superficiallyaffixed to the fastener. That is, although the fastener is supportedwithin and by the collation, the fastener can be rotated within thecollar. It may not be loosely held, but can nonetheless be rotated. Thishas two ramifications.

First, because the fasteners are loosely supported, the collation can beoverly flexible. This can result in increased corrugation of the stripin the tool magazine. Second, because the plastic is only looselyaffixed to the fastener, it has been observed the plastic collars andbridges fracture as the fastener is driven into the substrate. This hasbeen shown to result in the generation of debris, and in certaininstances substantial amounts of debris. At times, it has also beenfound that the collars collect under the fastener head, thus preventingthe fastener from being driven fully into the substrate. This may thusrequire a user to then drive, by hand, e.g., with a hammer, the fastenerthe remainder of the way into the substrate. Another drawback to theknown plastic collations was that because the collation material wasquite brittle, the downstream collation fractured, causing fasteners tobecome off-centered in the tool, which resulted in tool jams andmisfires.

In an effort to eliminate the drawbacks associated with the generationof debris and the accumulation of material under the fastener head, andoff-centered driven fasteners, a debris-free fastener was developed thatuses an adhesive-modified chemistry for the plastic collation materialin conjunction with preheating the fasteners prior to application(molding) of the collation.

It was found that the improved, debris-free collation generatedsignificantly less debris and that the plastic collation materialadhered well to the fastener shank. As a result, the plastic materialentered the substrate as the fastener was driven from the strip into thesubstrate. Such a fastener collation is disclosed in Shelton, U.S.patent application Ser. No. 11/383,032, filed May 12, 2006, Shelton,U.S. patent application Ser. No. 11/734,684, filed Apr. 12, 2007, andHeskel, U.S. patent application Ser. No. 11/935,541, filed Nov. 6, 2007,all of which are commonly assigned with the present application and areincorporated herein by reference.

While the above-noted fastener collations overcame many of the drawbacksin prior fastener collations, they were found to be very difficult tomanufacture. Using known manufacturing techniques resulted in too muchflow of the collation material and thus mis-formed collations, stickingof the collation material to the forming molds, and other manufacturingobstacles.

Accordingly, there is a need for a method for forming a plasticcollation system for strip-formed fasteners. Desirably, such a methodprovides a high quality collation formed on the fasteners. Moredesirably, such a method uses adhesive-modified materials for theplastic collation. More desirably still, such a collation forming methodcan be carried out in a high speed process with little to no waste orrejection of product. Most desirably, such a method forms a plasticcollation formulated from an adhesive polymer such as a polyolefin, suchthat when the fastener is driven from a driving tool, the collar portionremains adhered to the fastener so that the collar portion penetratesthe substrate with the fastener.

BRIEF SUMMARY OF THE INVENTION

A method for making a collated fastener assembly includes the steps ofarranging a plurality of fasteners in a row parallel to one another, andin a plane. The fasteners each have a head and a tip.

The fasteners are preheated to elevate the temperature of the fastenersand a molten polymer is applied onto the preheated plurality offasteners. The fasteners, with the molten polymer thereon, are conveyedbetween a pair of forming wheels and are maintained in the plane as theytraverse between the wheels.

The molten polymer material is molded onto the preheated fasteners andbetween adjacent fasteners to form a plastic molding having a collarencircling a shank of each fastener and a connecting portion betweenadjacent fasteners. A cooling vapor is sprayed onto the fasteners andthe plastic molding as the fasteners and the plastic molding exit frombetween the molding wheels. A gaseous cooling stream is forced over thefasteners and the plastic molding to cool the strip to form the fastenerassembly. The collation so formed does not use a paper tape. That is, itis a paper tape-less collation.

In a present method, the fasteners are preheated to a temperature ofabout 500 deg. F to about 620 deg. F, and preferably, about 600 deg. F.The molten polymer is heated to a temperature of about 400 deg. F. toabout 440 deg. F, and preferably about 410 deg. F. prior to beingapplied to the fasteners.

The cooling vapor is water. In a present method, the water vapor issprayed on the fastener assembly (after collation formation) from aboveand below, as the collation exits the forming wheels. To further coolthe assembly, a gaseous cooling stream, preferably air, is forced orblown over the fasteners.

A group of fasteners is severed from the assembly to form a strip ofpredetermined length or number of fasteners.

Following forming the strip, the fasteners can be preheated (at the tip)and a coating applied to the fasteners at about their respective tips.

In a present method, the fasteners are arranged parallel to one anotherand at an angle to a longitudinal axis of each fastener between zerodegrees and 90 degrees. A preferred angle is between about 15 degreesand about 35 degrees. The angle can be monitored to prevent out of anglefasteners from continuing through the collation process.

A preferred method included the step of aligning the fasteners with oneanother such that the head of each fastener is about aligned with thehead of each other fastener. The alignment step can be carried out priorto the step of preheating the plurality of fasteners.

The method can also include the step of realigning the fasteners withone another such that the head of each fastener is about aligned withthe head of each other fastener following the step of molding the moltenpolymer on to the preheated fasteners (before the polymer has fullyhardened or cured).

These and other features and advantages of the present invention will beapparent from the following detailed description, in conjunction withthe appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The benefits and advantages of the present invention will become morereadily apparent to those of ordinary skill in the relevant art afterreviewing the following detailed description and accompanying drawings,wherein:

FIG. 1 is a plan view of an exemplary nail collation formed inaccordance with a method of the present invention;

FIG. 2 is a schematic illustration of an apparatus for carrying out thepresent method;

FIGS. 2A and 2B are partial illustrations, as indicated in FIG. 2, ofthe apparatus and method carried out thereby;

FIG. 3 is a partial, enlarged view of fasteners being positioned in asingulating and conveying apparatus for preparing the fasteners forpositioning within the collation forming apparatus;

FIG. 4 is a view of the apparatus of FIG. 3 as seen from an oppositeperspective;

FIG. 5 is a front view of the apparatus showing the fasteners beingpositioned on a conveyor and showing both an alignment wheel and afastener angle sensing station;

FIG. 5A is a view taken along line 5-5 showing the fasteners aligned inthe conveyor (lying on the conveyor bands);

FIG. 6 is a perspective (front) view of the collation forming machineshowing the fastener preheating station;

FIG. 7 is a perspective (front) view of the forming wheels shown in adisengaged state and illustrating the polymer injectors disposed aboveand below the plane along which the fasteners are conveyed;

FIG. 8 shows the wheels in the closed or engaged state with the coolantvaporizers operating to spray vaporized water onto the fasteners;

FIG. 9 is an illustration of the fasteners secured in and engaged by theforming wheels;

FIG. 10 is a sectional view taken along line 10-10 of FIG. 9;

FIG. 11 is a perspective (front) view of the collation forming machineshowing the gas (air) cooling station;

FIG. 12 is a perspective (front) view of the cutting station showing thecutting blade moving down to engage a portion of a fastener strip;

FIG. 13 is a view similar to FIG. 12 showing the blade section pivotingto move with the strip as the cut is made;

FIG. 14 is a perspective (front) view of the turning plate for movingthe cut strips onto a second portion of the conveyor and showing anejection paddle in the extended (ejection) state;

FIG. 15 is an opposite side view of the turning plate and showing astrip of fasteners moving onto the second portion of the conveyor;

FIG. 16 is a top view of the nail strip on the second portion of theconveyor, as indicated at 16-16 in FIG. 15;

FIG. 17 is a perspective illustration of the tip coating preheater;

FIG. 18 is a perspective illustration of the tip coater;

FIG. 19 is a perspective (front) view of the end of the conveyor(downstream of the tip coating station);

FIG. 20 is a perspective (front) view of the conveyor and stacker;

FIG. 21 is a partial sectional view of the forming wheel shaft; and

FIGS. 22A-D are partial sectional views of the forming wheels and shaft,as taken along lines 22B-22B through 22D-22D.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred embodiment with the understanding that the presentdisclosure is to be considered an exemplification of the invention andis not intended to limit the invention to the specific embodimentillustrated.

It should be further understood that the title of this section of thisspecification, namely, “Detailed Description Of The Invention”, relatesto a requirement of the United States Patent Office, and does not imply,nor should be inferred to limit the subject matter disclosed herein.

Referring now to the figures and in particular to FIG. 1, there is shownan exemplary nail strip 10 having a plastic collation system 12 formedthereon. The collation 12 is as disclosed in the aforementioned U.S.patent applications to Shelton et al. and Heskel et al. In theillustrated strip 10, the nails 14 are positioned parallel to oneanother (e.g., with their axes A₁₄ parallel) and at an angle α of about20 degrees to the transverse direction (as indicated at 16) of the strip10. Other angles α (including zero degrees) are, however, contemplated.The nails 14 can be full head nails, D-head (or clipped head) nails orany other type of nail.

As discussed above, the nails 14 are collated and held to one another bythe plastic collation 12. The plastic collation 12 is molded to, overand around the shanks 18 of the nails 14, and connects each nail 14 toits adjacent nail or nails (that is, extends between the nails 14). Thecollation 12 is formed as a contiguous molding around and between thenails 14; nevertheless, for purposes of this disclosure, the molding,indicated generally at 20, is viewed as having a collar portion 22,which is that portion that encircles the nail shank 18, and a connectingportion 24, which is that portion that extends between and connectsadjacent collar portions 22. The collation 12 so formed does not use apaper tape. That is, it is a paper tape-less collation. Upper and lowermoldings or collations 20 are shown that are formed with structuresimilar to one another. The structure can, however, be different fromthe upper to the lower collations.

As set forth above and in the aforementioned patents to Shelton et al.and Heskel et al., the present nail collation 12 differs from previouslyknown plastic collations in a number of important aspects. First, ratherthan the plastic merely encircling and extending around and between thenails, the present collation 12 uses a material that is molded (orformed) around and adheres to the nails. It has been found that plasticthat is adhered to the nails, rather than merely molded around the nailsis advantageous in that the plastic material tends to remain on the nailshank during driving. That is, the collation 12 material is maintainedon the shank 18 as the nail 14 penetrates the substrate and thus entersthe substrate with the nail. Advantageously, much less debris isgenerated during driving of a nail from the present nail strip comparedto prior known nail strips.

In addition, adhesion of the plastic material to the nails 14 also hasbenefits vis-à-vis the rigidity of the nail strip 10. That is, when theplastic merely encircles the nail shanks, the plastic can slip aroundthe nail shanks. On the other hand, by adhering the plastic molding tothe shanks, the nail strip tends to become more rigid and is less likelyto flex and to corrugate.

A present material is an adhesive polymer, such as an adhesivepolyolefin, such as a maleic anhydride modified polyolefin, such aspolypropylene, polyethylene or the like. Other suitable materials, suchas epoxies, other resins, such as a polyvinyl alcohol (PVA) basedmaterial, an ethylene vinyl alcohol (EVA) based material, anacrylonitrile butadiene styrene (ABS) based material, ionomers, methylmethacrylates and the like. Fillers can also be used as can blends ofany of the materials, as suitable. Other materials will be recognized bythose skilled in the art and are within the scope and spirit of thepresent invention.

In forming the collation 12, the nails 14 are first surface conditionedto enhance adhesion. Conditioning is first carried out by washing thenails in a caustic solution. The solution is a mildly acidic ironphosphate solution or a mildly alkaline solution. It was found that sucha solution conditions the surface of the steel for adhesion with theplastic.

The conditioned nails 14 are fed into a collation forming machine 26. Inthe machine 26, the nails 14 are conveyed through a chute 28 andsingulated for positioning into a conveyor 30 at a preselected anglethat is the same as angle α, which in a present machine 26 and strip 10,is 22 degrees. The nails 14 are positioned on the conveyor 30 andaligned so that the tips 32 and heads 34 are all aligned with oneanother. In a present conveyor 30, the nails 14 are supported above andbelow (or outside of) the location at which the collations 12 will beformed. That is, the nails 14 are supported closer to the tips 32 andheads 34. A present conveyor 30 is formed from two continuous bands 36,38, each having a plurality of spaced apart grooves 40 formed therein,much like a saw blade. The bands 36, 38 rotate opposing one another inloops with one side of each loop 36 a, 38 a parallel and nearest to theopposing side of the other loop. The fasteners (nails 14) are carried inthe grooves 40 opposite one another as the two loops rotate, thuscarrying the nails 14 in a flat (horizontal) plane P along a straightpath through the collation forming machine 26. The bands 36, 38 aremovable relative to one another to adjust the angle α at which the nails14 lie in between the bands 36, 38. The bands are driven by a drive,such as that indicated at 101. Overall machine 26 operation is providedby a controller 103. The nails 14 are aligned head-to-head by analigning element 35.

The nails 14 are then conveyed to a preheater 42 where they arepreheated. A preheat temperature of about 500 deg. F. to about 620 deg.F. is a suitable range, and a preferred temperature is about 600 deg. F.for use with the maleic anhydride modified polypropylene. Othertemperatures may be better suited for other materials. Preheating iscarried out using flame heating, however, induction heaters or any othersuitable heating medium and method may be used. Heating is controlled bya sensor 44 (e.g., an infra-red sensor) immediately downstream of theheaters 42. In a present collation forming apparatus, upper and lowerheaters 42 a,b are used to heat the nails 14 from above and from belowto provide more consistent and even preheating.

As seen in FIGS. 7-10, the nails are then conveyed to a collationforming station 43 having a pair of forming wheels 46, 48. The wheels46, 48 are configured to carry and embrace the nails 14 and to mold theplastic (collations 12) between the nails 14 and grooves 50 formed inthe wheels 46, 48. Accordingly, the plastic is introduced to the nails14 immediately prior to the nails 14 entering the nip 52 between thewheels 46, 48. To effect plastic introduction or flow, a nozzle 54 ispositioned above the nails and another nozzle 56 is positioned below thenails 14, just prior to the forming wheels 46, 48. The plastic iscarried by the nails 14 into the space between the wheels 46, 48.

Plastic flow rate and temperature (from the nozzles 54, 56) are bothcontrolled to effect proper collation 12 formation. The plastic flow iscontrolled by controlling the extruder (not shown) that supplies theplastic, that is the plastic feed, and by a gate or valve 58 (one shown)at the nozzles 54, 56. Sensors 57 in the nozzles 54, 56 monitor thetemperature of the nozzles 54, 56. The plastic flows from the extruderexit to the nozzles 54, 56 through piping, tubing or conduit 60. In thatthe plastic is highly viscous, even though the extruder stops, plasticcontinues to flow from the extruder to the nozzles 54, 56. The valves 58are configured to stop the flow of plastic but are also configured toprevent the build up of pressure at the nozzles 54, 56 (which couldotherwise result in a shock of plastic when opened). As such, both a“shock” of plastic (upon resuming flow) and a drool of plastic(following isolation) are avoided. In this manner, flow is bettercontrolled and waste is reduced.

Temperature of the plastic is also tightly controlled by heaters 62located in the nozzles 54, 56. In this manner, the plastic is introducedto the nails 14 within a range of about 400 deg. F. to 440 deg. F, andpreferably about 410 deg. F. Control of the plastic temperature at thenozzle 54, 56 (tip) also prevents the plastic from freezing (hardening)at the tip 64, thus interrupting the collation forming operation.

At the exit of the wheels (as indicated at 66 in FIG. 8), the plastic ishot and is still in a flowable state. In order to stabilize thecollation 12, it is desirable to freeze the plastic—actually to cool theplastic—to a point such that an outer skin or layer is formed and isstable, although the plastic under the outer layer may still be in aplastic or flowable state. As such, the plastic is cooled by a spray ofchilled water vapor at the exit 66 of the wheels 46, 48. As shown inFIG. 8, vapor spray nozzles 68 are located to spray water vapor V downonto the top surface 70 (as seen in FIG. 9) and up onto the bottomsurface 72 of the collation 12 as it exits the forming wheels 46, 48, tobetter and more evenly cool the plastic collation 12 and facilitatecuring.

It has also been found that in order for the wheels 46, 48 to properlyconform the plastic 12 to the shape of the grooves 50 (in the wheels 46,48), and to release the plastic from the wheels 46, 48 without sticking(at the exit 66), a spray of chilled water vapor is applied to thewheels 346, 48. In a present method, a vapor spray is applied onto theupper wheel 46 from an upper spray nozzle 74 at a point prior to thewheels 46, 48 engaging the plastic 12 and the nails 14. In a presentarrangement, the water vapor is applied to the wheels at the apex of thewheels' path (e.g., the 12 o'clock position); however, the exactlocation can be varied to effect a desired machine configuration.

In addition to externally cooling and lubricating the forming wheels 46,48 (with the vapor spray 74), the wheels 46, 48 are cooled internally.As seen in FIG. 21-22A-D, cooling channels 76 are formed in the wheels46, 48 to maintain the wheels 46, 48 at a desired temperature. Thecooling channels 76 are fed through channels 78 formed in the shaft 80about which the wheels 46, 48 rotate. Seals 82 are positioned on theshaft 80 to maintain a seal between the rotating wheels 46, 48 and thestationary shaft 80. A liquid, preferably water is introduced into theshaft channels 78, flows into and through the wheels 46, 48 and out fromthe wheels 46, 48 through the channels 78 in the shaft 80. Cooling isprovided independently to each wheel 46, 48 through respective channels78 in the shaft 80. Other cooling fluids are, of course, contemplated bythe present invention.

The wheels 46, 48 are of a novel design. There are four wheels, whichinclude an upper 46 and a lower 48 wheel for each of the two collationsformed on the nails 14. The upper and lower wheels 46, 48 act in concertin forming each of the collations 12.

The wheels 46, 48 include a holding portion or groove 84 and a formingportion or groove 86. The nail 14 is held or secured in the holdingportion 84, while the forming portion 86 has a lightly larger sizegroove and is that portion of the wheel 46, 48 in which the plasticforms (flows) around the nail 14. Essentially, the forming portions 86of the upper 46 and lower 48 wheels form a mold cavity to form thecollar 22 and connecting portions 24 of the collation 12. That is, thereis sufficient space between the forming portions 86 (of the upper andlower wheels 46, 48) and the nail 14 to form the plastic collation 12(the collar portion 22 of the collation 12), and sufficient spacebetween the peaks 88 of the forming portions 86 to form the connectingportions 24 of the collations 12. The holding portions 84 are located,relative to the forming portions 84, to effect a desired collationprofile. That is, if it is desired to form the collar 22 concentric withthe shank 18, then the holding portion 84 is centered with the formingportion 86 (as seen in FIG. 10). Conversely, if it is desired to formthe collar 22 eccentric relative to the shank 18, then the holdingportion 84 is offset relative to the forming portion 86. In a presentmethod, the holding portion 84 is centered relative to the formingportion 86 so that the collar 22 and shank 18 are concentric.

The wheels 46, 48 are also configured to allow some variation in theangle α of entry of the nails 14. It will be appreciated that the nails14 are mass produced consumables and that the operating speed of themachine must be such that the collations 12 are formed at very highspeeds. As such, although a desired angle (e.g., 20 degrees) is set bythe various operations on the nails 14, there may be some slightvariation in the angle (up to about +/−2.5 degrees) in which thecollation is within acceptable tolerances. In order to accommodate thattolerance, and still provide an acceptable collation, the forming wheels46, 48 are permitted to move (rotate) relative to one another with asmall degree of freedom, and to allow some measure of misalignment ofthe nails 14 on the conveyor 30 relative to the wheels 46, 48.

As seen in FIG. 22B, the upper wheels 46 a,b and the lower wheels 48 a,bare mounted to one another by a stub 90 that extends between the wheels(e.g., 46 a,b). The stub 90 is rigidly mounted to one of the wheels(e.g., 46 a), but is mounted to the other wheel (e.g., 46 b) with aresilient element 92 (such as an O-ring) fitted on the stub 90 which isfitted into an opening 94 in the wheel 46 b. This provides the smalldegree of relative movement (or freedom) between the wheels 46 a,b. Inthis manner, if there is a small variation in the angle of the nails(within tolerances of course) as they enter the wheels 46, 48, the nails14 continue to move through the wheels 46, 48 without mishap. It will beappreciated that if the nails are rigidly held by the wheels, the nailscan, if the angle is slightly off, wedge into the wheels or not fitwithin the grooves, resulting in a failed collation, machine shut downand related time and material costs.

As the nails 14 move through and beyond the forming wheels 46, 48 theyare held down on the conveyor 30 by a pair of hold down rails 96. Theserails 96, or skates, do not apply any significant pressure on the nails14, but hold them down on the conveyor 30 to prevent the nails 14 fromlifting with the wheels 46 (as they exit the wheels) or from lifting asthe plastic 12 cools and cures. Shortly downstream of the vapor spraycooling 68, the rails 96 end and the nail collations are continued inthe conveyor 30.

At this point in time, the outer layer of the plastic has begun toharden or cure, but the material between the outer layer and the body ofthe nail, although highly viscous, is still in a formable state. A siderail 98 is positioned downstream of the hold-down rails 96 to (axially)align the fasteners tip-to-tip or head-to-head. Typically any adjustmentin the alignment is minimal, if needed at all, but can be done with thecollation material in this state.

A further cooling step is carried out using air coolers 100 to force agas, preferably chilled air, over the nails 14. Following the coolingstep, the collations are sufficiently cooled and cured to be cut intostrips 10 of a predetermined length or number of nails 14. The nailstrips 10 are cut at a cutting station 102 that includes a cutter blade104 that is mounted to a reciprocating carriage 106. The carriage 106 isalso configured to pivot (as at 108) so that the cut can be effected onthe moving strip 10 (that is, without slowing or stopping the strip). Abiasing element 110, such as a spring returns the carriage 106 (and thusthe cutter blade 104) to the home position following the cut.

Once cut, the nail strips 10 have a tip coating applied. Prior tocoating, the nail tips 32 are heated, such as by the illustrated flameheater 112. Induction heaters or the like, as suitable, may also beused. The coating is then applied. The coating enhances or easespenetration of the nails 14 into a substrate, and can also enhance theholding power of the nails 14. The coating can be applied by conveyingthe nails 14 through a tip coater 114 that includes, for example, a pairof rotating foam rollers 116, 118, one of which 116 is positioned in areservoir 120 of the coating material (liquid). Following coating anddrying, the nail strips 10 are then stacked for packaging at a stacker122.

It will be appreciated that although certain specific details, forexample plastic temperature ranges, preheat temperatures and the likeare provided, these specific details are those for use with the notedmaleic anhydride modified polypropylene and it is anticipated that thespecific temperatures and the like will vary for other materials.

All patents referred to herein, are incorporated herein by reference,whether or not specifically done so within the text of this disclosure.

In the present disclosure, the words “a” or “an” are to be taken toinclude both the singular and the plural. Conversely, any reference toplural items shall, where appropriate, include the singular.

From the foregoing it will be observed that numerous modifications andvariations can be effectuated without departing from the true spirit andscope of the novel concepts of the present invention. It is to beunderstood that no limitation with respect to the specific embodimentsillustrated is intended or should be inferred. The disclosure isintended to cover by the appended claims all such modifications as fallwithin the scope of the claims.

What is claimed is:
 1. A method for making a collated fastener assemblycomprising the steps of: arranging a plurality of fasteners in a rowparallel to one another, the fasteners being arranged in a plane andspaced from one another to define a gap therebetween; preheating theplurality of fasteners to elevate the temperature of the fasteners;applying a molten polymer material onto the preheated plurality offasteners; conveying the fasteners with the molten polymer thereon intoa mold cavity; maintaining the fasteners in the plane; molding themolten polymer material onto the preheated fasteners and betweenadjacent fasteners to form a molding having a collar encircling a shankof each fastener and a connecting portion between adjacent fasteners,the molding maintaining the space between the fasteners; and introducinga cooling stream onto the fasteners and the molding as the fasteners andthe molding exit from the mold cavity.
 2. The method of claim 1 whereinthe fasteners are preheated to a temperature of about 500 deg. F. toabout 620 deg. F.
 3. The method of claim 1 wherein the molten polymer isheated to a temperature of about 400 deg. F. to about 440 deg. F. priorto applying to the fasteners.
 4. The method of claim 1 wherein thecooling stream is a water stream.
 5. The method of claim 4 wherein thewater stream is a water vapor stream.
 6. The method of claim 1 whereinthe step of introducing the cooling stream onto the fasteners and themolding is the introduction of a first cooling stream and furtherincluding the step of introducing a second cooling stream onto thefasteners and the molding.
 7. The method of claim 6 wherein the secondcooling stream is a gaseous cooling stream.
 8. The method of claim 7wherein the gaseous cooling stream is an air cooling stream.
 9. Themethod of claim 1 including the step of, forming in the molding, adesired line of separation of a fastener including its collar and theconnecting portion between the fastener and a next subsequent fastener,from the fastener collation assembly.
 10. The method of claim 9 whereinthe desired line of separation is defined by a notch formed at about thecollar and the connecting portion.
 11. A method for making a collatedfastener assembly comprising the steps of: supporting a plurality offasteners in a row parallel to one another, the fasteners being arrangedin a plane and spaced from one another to define a gap therebetween;preheating the plurality of fasteners to elevate the temperature of thefasteners; applying a molten polymer material onto the preheatedplurality of fasteners; continuously conveying the fasteners with themolten polymer thereon into a mold cavity; securing the fasteners withinthe mold cavity; molding the molten polymer material onto the preheatedfasteners and between adjacent fasteners to form a molding having acollar encircling a shank of each fastener and a connecting portionbetween adjacent fasteners, the molding maintaining the space betweenthe fasteners; and forcibly cooling the fasteners and the molding as thefasteners and the molding exit from the mold cavity.
 12. The method ofclaim 11 wherein the forcibly cooling step is carried out by applying acooling stream to the fasteners and the molding.
 13. The method of claim12 wherein the cooling stream is a water stream.
 14. The method of claim13 wherein the water stream is a water vapor stream.
 15. The method ofclaim 11 wherein the step of introducing the cooling stream onto thefasteners and the molding is the introduction of a first cooling streamand further including the step of introducing a second cooling streamonto the fasteners and the molding.
 16. The method of claim 15 whereinthe second cooling stream is a gaseous cooling stream.
 17. The method ofclaim 16 wherein the gaseous cooling stream is an air cooling stream.18. The method of claim 11 including the step of, forming in themolding, a desired line of separation of a fastener including its collarand the connecting portion between the fastener and a next subsequentfastener, from the fastener collation assembly.
 19. The method of claim18 wherein the desired line of separation is defined by a notch formedat about the collar and the connecting portion.